Compression molding of thermoplastic polyurethane composites for shape memory polymer actuation

Background: Soft actuation relies on materials that are lightweight, flexible, and responsive to external stimuli. In biomedical applications, miniaturization and biocompatibility are key requirements for developing smart devices. Thermoplastic polyurethane (TPU) is particularly attractive due to its elasticity, processability, and biocompatibility; however, an improvement in its shape-recovery performance would significantly enhance its suitability for actuation systems. This study aims to develop TPU-based shape memory polymer (SMP) composites with improved functional behavior for biomedical applications. Methods: TPU was modified with aluminum nanoparticles (AlNPs) and multi-walled carbon nanotubes (MWCNTs), incorporated individually (1 wt.% and 3 wt.%) and in hybrid combinations (MWCNT:AlNP ratios of 2:1, 5:1, and 10:1). Samples were produced by compression molding and characterized through thermal, mechanical, electrical, and shape-recovery tests, supported by morphological analysis. Results: AlNPs moderately improved thermal conductivity, while MWCNTs significantly enhanced electrical conductivity and doubled the recovery force compared with neat TPU. Hybrid composites showed intermediate properties, with the 5:1 MWCNT:AlNP ratio offering the best balance between recovery force and activation speed. Conclusions: The synergistic combination of MWCNTs and AlNPs effectively enhances TPU’s multifunctional behavior, demonstrating strong potential for soft actuation in biomedical devices.